AR35.31-P-0550C Disassemble/Assemble Rear Axle Center Assembly, Adjust Gear Set
Disassemble/assemble Rear Axle Center Assembly, Adjusting Gear Set
1 Remove rear axle center assembly (50)
NOTE: Drain rear axle oil by unscrewing oil drain plug
2 Clamp rear axle center assembly in assembly stand
3 Remove cover (54)
4 Pull locking rings (30) off both connecting flanges (33 or 33a, 33b)
5 Pull out connecting flange (33 or 33a, 33b)
6 Press off left and right radial seal ring (32, 32a, 70j)
- Vehicles with ASD
- Vehicles with ASR
- Vehicles without ASD/ASR
7 Remove hydraulic line (701)
- Vehicles with ASD
8 Detach ring cylinder (70)
- Vehicles with ASD
9 Remove oil deflector (71)
- Vehicles with ASD
10 Remove right circlip (29) from rear axle housing using spreader
NOTE: Mark locking ring
11 Remove left circlip (29) from rear axle housing
NOTE: Mark locking ring
12 Remove both tapered roller bearing outer races (11a) from rear axle housing
NOTE: Mark tapered roller bearing outer races
13 Remove differential (13) from rear axle housing
14 Pull both tapered roller bearing inner races (11b) off differential (13)
NOTE: Mark tapered roller bearing inner races
15 Slacken and remove locking bolts (13a) from ring gear (47a)
NOTE: Mark position of crown wheel in relation to differential
16 Carefully press crown wheel (47a) off differential (13)
17 Slacken and unscrew twelve-point collared nut (40) from joint flange (41)
18 Detach joint flange (41)
NOTE: If necessary mark position of joint flange in relation to drive pinion As of 01.04.98
19 Press drive pinion (47) out of rear axle housing
20 Press radial seal (42) out of rear axle housing
NOTE: Use suitable screwdriver
21 Remove tapered roller bearing inner race (43d) with thrust washer (43a)
22 Remove tapered roller bearing outer race (46b, 43e) and shim (45) from rear axle housing
23 Remove spacer sleeve (44) with bearing washers (48) from drive pinion
24 Pull ABS gear (49) off drive pinion (47)
- Vehicles with ABS except vehicles with ETS,ASR, ESP
25 Pull tapered roller bearing inner race (46a) off drive pinion (47)
26 Check all parts for reusability and replace if necessary
NOTE: If the contact surfaces of the connecting and joint flanges are severely galled by the radial seal, the flanges must be replaced
27 Checking drive pinion (47) and ring gear (47a) for match-up number
- Only lapped gear sets up to approx 06/95 have a match-up number
NOTE: The running noise made by each lapped gear set is checked and both parts are marked with a consecutive match-up number.
Assemble, Adjust Gear Assembly
28 Press tapered roller bearing inner race (46a) onto drive pinion (47)
29 Press ABS gear (49) onto drive pinion (47)
- Vehicles with ABS except vehicles with ETS,ASR,ESP
30 Calculate shim (45) and install in rear axle housing
31 Install tapered roller bearing outer races (46e, 43b) in rear axle housing
32 Install spacer sleeve (44) with bearing washers (48) on both sides on drive pinion
NOTE: Always replace spacer sleeve and bearing washers
33 Insert drive pinion (47) into rear axle housing (50)
NOTE: Support drive pinion with removal and installation fixture
34 Clip thrust washer (43a) onto tapered roller bearing inner race (43d)
- Rear axle center assembly
35 Install tapered roller bearing inner race (43d) on drive pinion and press in together with radial seal ring (42)
36 Sliding joint flange (41) onto drive pinion
NOTE: Observe any markings Coat contact face for radial seal ring with universal hypoid gear oil
37 Screw on twelve-point collared nut (40)
38 Adjust friction torque of drive pinion bearing
39 Checking adjustment dimension of drive pinion
40 Secure twelve-point collared nut (40) at joint flange
41.1 Dismantle and assemble differential gear (13)
- Without ASD
41.2 Dismantle and assemble ASD differential (13)
- with ASD
42 Mount crown wheel (47a) on differential
NOTE: Observe markings made on crown wheel and differential
43 Press tapered roller bearing inner races (11b) onto differential
44 Insert differential (13) into rear axle housing
NOTE: Secure differential with drift
45 Insert left tapered roller bearing outer race (11 a) in rear axle housing
46 Insert left circlip (29)
NOTE: Install locking ring previously removed and marked to achieve the basic pretension of the rear axle housing
47 Remove right drift from differential
48 Insert right tapered roller bearing outer race (11 a) into rear axle housing
49 Pre-tension (spreading) rear axle housing with spreader
NOTE: Ensure that the "0" setting on the dial indicator with contact arm is retained
50 Install right circlip (29)
NOTE: Install circlip previously removed and marked to achieve the basic pre-tension of the rear axle housing
51 Release tension of rear axle housing
52 Measure expanded dimension (expansion) of rear axle housing
53 Remove spreader from rear axle housing
54 Measure gear backlash between ring gear and pinion, correct if necessary
CAUTION: The adjustment of the tapered roller bearing or gear set is OK if the spread dimension (expansion) of the rear axle housing and the gear backlash are within the range of the specifications
55 Ensure correct seat of circlip (29)
56 Install oil deflector (71)
- Vehicles with ASD
NOTE: Ensure correct seating
57 Mount ring cylinder (70)
- Vehicles with ASD
- Coat ring cylinder at circumference of O-ring with hydraulic oil
58 Attach hydraulic line (701)
59 Press radial seal rings (32 or 32a, 70j) into rear axle housing (50)
- Replace radial seal ring and coat lip with universal hypoid gear oil.
60 Push spacer rings (31 b) onto connecting flange (33 or 33a)
61 Install connecting flanges (33 or 33a, 33b) in differential (13)
62 Place circlips (30) onto connecting flanges
- Except model 203
- Replace circlip
63 Check and adjust end play of connecting flange
- Except model 203 and vehicles without ASD
NOTE: For vehicles with ASD, the end play need not be adjusted
64 Mount end cover (54)
NOTE:
- If a replacement end cover is fitted, be sure to check whether or not the sealing surface is machined Use suitable sealant
- End cover with machined sealing surface in models 124, 129, 201 and models 170, 202, 208, 210 up to 07.05.00
- End cover with non-machined sealing surface in model 203 and models 170, 202, 208, 210 as of 08.05.00
65 Replace rear axle breather (55) at end cover (54)
66 Remove rear axle center assembly from assembly frame
Install
67 Install rear axle center assembly (50)
68 Fill rear axle oil
69 Bleed ASD hydraulic system
- Vehicles with ASD